Download Applied Air IFD SERIES Operating instructions

IOM-IFD-2
INSTALLATION, OPERATION AND MAINTENANCE
MANUAL FOR THE IFD SERIES DUCT FURNACES
COPY TO BE MAINTAINED IN A LEGIBLE CONDITION WITH THE DUCT FURNACE.
READ THIS MANUAL CAREFULLY BEFORE INSTALLING AND OPERATING THIS FURNACE
PLEASE GIVE MODEL NO. & SERIAL NO. WHEN CONTACTING THE FACTORY OR
REPRESENTATIVE FOR INFORMATION AND/OR PARTS
FOR YOUR SAFETY
The use and storage of gasoline or other flammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open flame.
4. Immediately call you gas supplier.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause injury or
death. Read the installation, operating and maintenance instruction thoroughly before
installing or servicing this equipment. This duct furnace must only be serviced by qualified
personnel. Do not tamper with the duct furnace or controls.
Certified for installation in the USA and Canada
Duct Furnace: ANSI Z83.8-1996/CGA 2.6-M96
Duct furnace
Model #:
Duct furnace
Serial #:
Service contractor:
Applied Air Systems
4830 Transport Drive
Dallas, Texas
75247
Tel #:
Date Installed:
1
USA
CONTENTS
1.0 INTRODUCTION……………………………………………. 3
1.1 Notes…………………………………………………. 3
1.2 Caution………………………………………………. 3
1.3 Warranty…………………………………………….. 4
2.0 INSTALLATION………………………………………………. 5
2.1 Receiving and Storing……………………………. 5
2.2 Lifting and Handling………………………………. 5
2.3 Installation Clearances…………………………… 6
2.4 General Installation……………………………….. 7
2.5 Drains and Traps…………………………………... 7
2.6 Combustion Air Requirements………………….. 8
2.7 Exhaust Stack and Venting………………………. 8
2.8 Gas Installation…………………………………….. 9
2.9 Electrical Installation……………………………… 10
3.0 OPERATING INSTRUCTIONS……………………………… 11
3.1 Start-Up Check List…………………………………. 11
3.2 Combustion Operation……………………………... 12
3.3 High Altitude Operation..……………………………13
3.4 Shut Down Instructions……………………………. 14
3.5 Suggested Tools……………………………………. 14
3.6 Troubleshooting Guide…………………………….. 15
3.7 Final Checks And Adjustments……………………17
4.0 MAINTENANCE………………………………………………. 18
4.1 Recommended Maintenance……………………….18
5.0 4.2 Recommended Spare Parts………………………..
19SPECIFICATIONS………………………………………
……. 20
Attached section Duct furnace Details
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1.0 INTRODUCTION
The following Owner's Manual for the Applied Air equipment outlines installation,
operation and service requirements for IFD series of indirect gas fired duct furnace.
The IFD series is ETL certified. Certification includes indoor models, high altitude
applications, and a wide range of operational conditions. For more information on
certification, please contact the Customer Service department at Applied Air Systems.
These manuals have been prepared to assist in the installation, operation and
maintenance of your duct furnace. It is good practice to know as much as possible
about your duct furnace before trying to install or operate it. Read the contents carefully
before proceeding. Due to the custom nature of Applied Air equipment, not all
possibilities are addressed in this manual. In cases where a special application is not
covered, the customer or installer can obtain information from Applied Air's sales
representative or the Applied Air factory. Additional component specific manuals may
be included with this manual, i.e. burner manuals, to assist in the maintenance or
repairs of the furnace.
1.1 Notes
1. Please disregard any information and/or data covering optional components not
supplied with the duct furnace.
2. Do not destroy or remove information from this instruction manual.
instruction in the electrical enclosure of the duct furnace.
Leave this
3. Field installed fuel conversion kits are not available. If your fuel requirements change
contact the factory about converting your furnace to/from natural or LP gas.
1.2 Caution
1. Regulations require that service mechanics that work on combustion equipment must
be qualified.
2. Contact with moving parts can cause injury or property damage. Automatic control
devices may start the duct furnace without warning. To prevent accidental start-up, the
maintenance personnel should always lockout all power supplies before working on
Applied Air equipment. A duct furnace will often have more than one power connection
point; disconnect all sources of power before servicing. Even when locked out
electrically, fans located in a parallel or series fan system may be subject to wind
milling.
3. Refer to the rating plate for fuel input and supply pressures.
4. DO NOT attempt to start the burner if the duct furnace is full of vapor or gas, or if
the combustion chamber is very hot.
5. DO NOT use gasoline, crankcase oil or any oil containing gasoline for fuel.
6. DO NOT burn garbage or paper in this heating system.
combustible material near the duct furnace.
Never leave paper or
7. SHUT OFF the manual fuel supply valve if the burner is shut down for an extended
period of time.
8. Ensure all access and clean-out doors are secure before starting the blower and burner.
3
1.3 Warranty
Applied Air warrants all Applied Air products to be free from defects in material or
workmanship, under normal use and service, for a period of twelve (12) months from date
of shipment, unless a start-up form is on file and accepted by Applied Air, in which case the
warranty is twelve (12) months from date of start-up, or eighteen (18) months from date of
shipment, which ever comes first. Warranty void if any of the following occur:
1. A qualified heating contractor in accordance with provisions of this service manual and
safe practices does not install the duct furnace.
2. The duct furnace was not subject to only normal use in service and was misused,
neglected, altered or otherwise damaged.
3. The duct furnace is allowed to operate during building construction period.
4. The duct furnace is installed without proper clearance to combustible materials or
located in a confined space without proper ventilation for combustion. (See section 2.0
Installation)
5. The duct furnace is operated in atmospheres containing flammable vapors, chlorinated
or halogenated hydrocarbons.
6. The temperature rise across the duct furnace is in excess of that shown on the duct
furnace rating plate (see Section 3.0 Operation Instructions).
7. The duct furnace was operated at any time outside its published capacity and/or any
other fuel than prescribed.
8. Field wiring is not in accordance with the wiring diagram furnished with the duct furnace.
9. Any automatic controls were inoperative during duct furnace operation.
10. Proper maintenance is not provided on a regular basis as outlined (See Section 4.0
Maintenance).
4
2.0 INSTALLATION
CAUTION
The equipment installation shall conform with local building codes, or in the absence
of local codes in accordance with the Installation Code for Gas Burning Appliances
and Equipment, CAN1-B149 in Canada or Z223.1 in USA, and applicable
Provincial/State Regulations; which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
Installation may be in accordance with applicable standards including;
Installation Code for Natural Gas Burning Appliances and Equipment, CAN1-B149.1
Installation Code for Propane Burning Appliances and Equipment, CAN1-B149.2
Installation Code for USA National Fuel Gas Code, Z223.1
Standard on Aircraft Hangars, ANSI/NFPA 409
Standard for Parking Structures, ANSI/NFPA 88A
Standard for Repair Garages, ANSI/NFPA88B
Safety First: Ensure that all practices of the Construction Safety Association and
O.S.H.A. as well as practical common sense are continuously in use.
2.1 Receiving and Storing
1. INSPECT the duct furnace carefully upon arrival for any shipping damage. If damaged,
sign the carrier’s bill of lading with a notation “Damaged During Shipment” or ”Received
Damaged.”
2. Check the packing slip against all items received. If any items are missing, sign the
carrier’s bill of lading with the notation “Shipment Received Less Item …….”
3. When unloading the duct furnace follow the 2.2 Handling and Suspension section
following.
4. All control components and accessories that are shipped separately for field installation
should be stored in a locked storage area.
5. If the duct furnace and/or its accessories cannot be installed immediately, it should be
stored in a dry and clean area. If this is not possible and the duct furnace must be
stored outside, it should be protected from the weather with tarpaulins or plastic
coverings.
2.2 Lifting and Handling
1. Before the duct furnace is placed in its installed location, check that the hoisting
equipment and permanent supports are adequate for the weight as indicated on the
General Arrangement Drawing plus a weight allowance for servicemen and equipment.
5
2. NOTE: Hooks, jacks, slings, or chains must not be applied to the duct furnace casing or
to any of its components. Every duct furnace is supplied with lifting lugs unless
otherwise specified, use ALL lifting lugs on each duct furnace section. The lifting points
must be at the center of gravity to assure that the duct furnace is level during hoisting
and prior to setting. Lifting lugs are not to be used for permanently suspending the
furnace.
3. The duct furnace is to be leveled with the hanging load distributed equally to all lugs.
DO NOT hang or support the duct furnace from the service platform (if supplied.)
4. When hoisting indoor duct furnace to be suspended, it is recommended that a separate
chainfall be used at each lifting point. The chainfalls should only be removed after the
duct furnace supports are permanently installed.
5. Use spreader bars to provide vertical lifting force only at the lifting points, and to prevent
damage to the duct furnace. Provide additional blocking and coverings as required to
prevent damage to the duct furnace finish and/or components. Assure that all crating
and packaging used for shipment that may interfere with the placing or assembling of
the duct furnace is removed before lifting the duct furnace into place.
6. If a fork lift truck is used, caution must be taken to ensure that the forks do not damage
the duct furnace or its components. The forks must extend beyond the opposite side of
the duct furnace to prevent damage.
7. Check that there are, or will be, no explosive, flammable or toxic vapors, or abnormally
excessive dust in the area where the duct furnace is located.
8. Check that the duct furnace is securely mounted and braced and will not be subject to
swaying or movement that would put a stress on fuel or electrical connections.
9. Mount and install all accessory items that may have been shipped separately for field
installations; i.e., filter boxes, filter, inlet cowls, louvers, discharge heads, plenums,
dampers, etc.
2.3 Installation Clearances
For Safety and Service, the following minimum clearances and guidelines shall be
observed:
Model
IFD
Location
Top
Front
Back
Side
Type of Floor
10"
10"
10"
20"
Combustible or
non-combustible
1. There should be a minimum 36" clearance from the front of the duct furnace flue outlet
on outdoor duct furnace.
2. The National Electrical Code (NEC or CEC) requires a minimum of 36" service space
between the face of any electrical enclosure and any wall or obstruction.
3. Provide sufficient clearance to open doors, install piping and ducting, flame observation
port, high limit switch, control panel, main fan motor, and all access panels.
6
2.4 General Installation
1. It is the customer and installation personnel responsibility to determine if the duct
furnace is equipped with all of the safety devices required for the particular application.
Safety considerations include the accessibility of the equipment to non-service
personnel, the provision of electrical lockout switches, maintenance procedures, and
automatic control sequences.
2. Duct furnaces must be level. Failure to provide a level-mounting surface for the duct
furnace will result in a variety of operational problems.
3. Clearly identify all emergency shut off devices.
4. Make duct connections to the casing by applying caulking around the connection and
screwing flanged ducts directly to the casing and/or flange with self-tapping sheet metal
screws. It is important to seal all duct connections to prevent air leakage and system
performance problems. Ducts connected to the furnace shall have removable access
panels on both the upstream and downstream sides of the furnace. These openings
shall be accessible when the furnace is installed and shall be sized to allow the
observation of smoke or reflected light inside the casing to indicate the presence of
leaks in the heat exchanger. The covers for the openings shall be attached in such a
manner as to prevent leaks.
5. The furnace must not be operated in the presence of chlorinated vapors. When such
vapors mix with the products of combustion, highly corrosive compounds result, which
will cause the premature failure of the heat exchanger and other components.
6. If installing a duct furnace model, IFD, the furnace is connected to a return air duct or
any other inlet air restriction, the duct furnace shall be installed on the positive pressure
side of the air-circulating blower.
7. When the duct furnace is installed in an enclosed duct furnace room it is imperative that
the duct furnace room itself is not used as an air plenum. Ductwork must be used for all
supply and return air to and from the duct furnace, as well as any other fans, which may
be installed in the same room.
2.5 Drains and Traps
1. Heat Exchanger Condensate - These duct furnaces are supplied with a condensation
removal pipe connection. Condensate from the heat exchanger is acidic and may
contain chemical compounds requiring special drainage. The drain must be installed in
accordance with all plumbing codes. The condensate is to be drained via 1/2" PVC or
steel pipe with an indirect connection to the plumbing wastes. Where a condensate
neutralizer is used, an overflow shall be provided such that condensate will be directed
to the drain in the event that the neutralizer becomes plugged. Indoor installations
typically require a condensate trap to be installed to prevent combustion gases entering
the space. Outdoor duct furnaces may require special attention to drains to prevent
freezing and clogging of the drain line.
2. Since the condensate is drained by gravity, avoid long runs of drain piping. If a long run
of trapping cannot be avoided or the piping has water flow restrictions such as several
elbows, add extra height to provide enough hydrostatic head to overcome the frictional
losses. Always slope piping down a minimum of 1/8" per foot in the direction of the flow.
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2.6 Combustion Air Requirements
1. If the duct furnace is installed in furnace rooms, confined areas or low-leakage
construction buildings, provisions must be made for combustion air. The duct furnace
shall be located such that a negative pressure will not be created, which will starve the
burner of combustion air. The combustion air vent piping should not be less than 24 Ga.
galvanized steel, and not more than 50 feet nor less than 10 feet in length.
2. NOTE: Outdoor Combustion Air Kits should be used where there is a possibility of
exposure to substances such as:
Chlorinated laundry products
Carbon tetrachloride
Permanent wave solutions
Halogen-type refrigerants
Chlorinated waxes and cleaners
Cleaning solvents (perchloroethylene)
Chlorine based pool chemicals
Printing inks, paint removers, etc.
Water softening chemicals
Cements and glues
De-icing salts or chemicals
Anti-static fabric softeners
Masonry acid washing materials
Hydrochloric acid
3. NOTE: The above also applies to the circulating air intake. Use 100% external air.
4. Combustion air shall be provided at a rate of at least 10 CFM, or 1 square inch of free
opening, per hour of rated input. If a separate mechanical means provides this air, an
interlock with the combustion blower shall be provided.
5. In some cases, local authorities require that combustion air be ducted directly to the
burner. Refer to the relevant standards in the current CAN1-B149.1, CAN1-B149.2,
B139 and Z223.1 in USA.
2.7 Exhaust Stack and Venting
1. Installations must be in accordance with the requirements of authorities having
jurisdiction. Flue outlet pressure must not exceed rating on the name plate for
maximum over fire pressure on positive fired chambers, or maintain the over fire draft
pressure for the furnace on negative fired chambers with I.D. fans.
2. A vent connector shall be equivalent to a minimum of 24 Ga. galvanized steel. It shall
have a minimum clearance of at least 9" to combustible material. All horizontal runs
should have a minimum rise of 1/4" per foot of horizontal run in the direction of
discharge.
3. Refer to the rating plate for the category of appliance to select the venting. Consult the
authorities having jurisdiction, and use a gastight, watertight venting system constructed
of material resistant to corrosion by condensate.
4. The National Fuel Gas Code, ANSI Z223.1, specifies a 4 foot (1.22m) horizontal vent
terminal clearance from gas and electric meters, regulators and relief equipment. The
Canadian B149.1, Natural Gas Installation Code specifies a 6 foot (1.83m) horizontal
vent terminal clearance to gas and electric meters and relief devices.
5. Do not install dampers or other restrictive devices in the flue vent pipe.
6. Stack terminations must be kept to approved distances from fresh air intakes, rooflines,
etc. Guy wires may be required to brace the stack above rooflines.
8
7. The stack should be installed in such a manner that access to the appliance is not
obstructed. Do not support the weight of the stack on the flue connection of the heating
section.
8. Approved methods must be followed when putting the stack through walls, floors, roofs,
etc.
9. Any exhaust stack shall have a minimum of at least 36" clearance to combustible
material.
10. The pressure measured with a manometer at the test port in the burner compartment
must not exceed the "Maximum Overfire Positive" pressure on positive fired duct
furnaces.
11. Gravity Venting Adjustment: The flue draft should be adjusted at the damper of the
burner fan when the duct furnace is operating on high fire.
12. Power Venting Adjustment: The flue draft should be adjusted at the damper of the
induced draft (I.D.) fan when the duct furnace is operating on high fire.
2.8 Gas Installation
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
1. Installations must be in accordance with the requirements of authorities having
jurisdiction. Emergency manual shut down valve should be provided upstream of piping
to duct furnace and labeled for quick identification. Color-coding of pipe may be required
and is recommended. Carefully check the duct furnace rating plate for the fuel type,
supply pressure and input rating.
2. Gas supply pressure, higher than 14"w.c. (3.5kPa), requires an additional field installed
gas regulator. Install the high-pressure gas regulator and relief valve (if supplied), in the
gas line to the duct furnace. The high-pressure regulator and relief valve should be, if
possible, mounted at least 5 to 10 feet upstream from the appliance regulator on the
duct furnace. Run the gas line to the duct furnace and mount these items so as not to
interfere with or hinder access to the duct furnace or any of its components.
3. The gas line to the duct furnace should be taken off the top of the main gas line. An
approved drip leg with screwed cap should be installed at the bottom of the vertical drop
in the gas line to the duct furnace.
4. If not provided with vent limiters, vent the main gas appliance regulator, the pilot
regulator, and the gas pressure switches to the outdoors. The high-pressure regulator
relief valve and normally open vent valve (if supplied) must be vented to atmosphere
separately from all of the components in accordance with applicable codes. Vent lines
should terminate outside the building with a turndown elbow and fly screen.
9
2.9 Electrical Installation
CAUTION
Installations must be in accordance with the requirements of authorities having
jurisdiction. Do not cut holes in the floor of outdoor model duct furnaces as the
bottom of the duct furnace has been made waterproof. Wiring diagrams are included
in the control cabinet of the duct furnace. The power requirements are indicated on
the duct furnace rating plate. Authorities having jurisdiction should be consulted
before installations are made.
Installation may be in accordance with applicable standards including;
The Canadian Electrical Code Part 1 - CSA Standard C22.1
National Electric Code in USA, (ANSI / NFPA 70)
1. Field wiring is indicated on the wiring diagram, typically dashed lines. Where field wiring
of the control circuit is required, take care to size the field wiring for a maximum 10%
voltage drop. The VA rating of the transformer can be assumed to be the maximum
load.
2. Reconnect all disconnected wiring on the duct furnaces that were split for shipment.
3. When connecting a power supply to a three-phase motor, take care that the threephase wiring gives you the correct motor and blower rotation on all motors.
4. Should any original wire supplied with the furnace have to be replaced, it must be
replaced with wiring material having a temperature rating of at least 105°C. See fieldwiring diagram for requirements for shielded or twisted wire.
5. Temperature controllers, limit controllers, remote selector switches, remote panels, door
switches, or any other auxiliary electrical item shall be connected to the terminals
provided, as shown on the wiring diagram.
6. If a space thermostat is used with the furnace, locate the thermostat so that cold drafts
and hot discharge air streams do not affect its performance. Do not mount the
thermostat on the casing of the duct furnace, or any other location where it may be
affected by radiated and conducted heat. Refer to the instruction furnished with the
thermostat for further details.
10
3.0 OPERATING INSTRUCTIONS
CAUTION
Provincial and State regulations require that service mechanics must be
licensed to work on combustion equipment.
The duct furnace should not be started or serviced by unqualified personnel.
Although many maintenance items do not require the service of a licensed mechanic,
it is recommended that a licensed mechanic supervise any work done on the duct
furnace by unlicensed personnel. Unqualified personnel should not be allowed to
work unsupervised.
•
•
•
•
Refer to the notes in section 1.0, at the beginning of this guide before continuing
Read the below sections before operating this furnace.
DO NOT attempt to start the burner if the duct furnace is full of vapor or
gas, or if the combustion chamber is very hot.
Before starting up the furnace, study and familiarize yourself with the wiring
diagram, sequence of operation, flame safeguard, controls, gas train, and burner.
3.1 Start-Up Check List
NOTE: When starting up the duct furnace for the first time or if the duct furnace has been
shut down for an extended period of time the same start-up procedures, as outlined in
sections 3.2 and 3.3, should be followed.
1. Set all electrical switches and main duct furnace disconnect switch to "OFF" position.
2. Close all duct furnace manual valves and field piping valves.
3. Check the duct furnace supply, discharge, and vent to make sure they are clear and
free from any obstructions. Check to make sure all applicable dampers are open or
adjusted to their correct settings.
4. Purge all the air from the gas lines per gas codes. Check all connections for leaks and
correctness. Ensure that the inlet pressure complies with the rating plate.
5. Inspect all electrical wiring, both field and factory installed, for loose connections.
Check all fuse blocks to determine that all fusing is installed.
6. Check all motor thermal overload settings against the rating plate figures.
7. Turn duct furnace disconnect switch "ON" (control switches are still "OFF") and check
the supply voltage. Voltage must be within 10% of nameplate rating. If not, consult the
electric utility company and have the voltage condition corrected before start-up.
8. Check set points of temperature limiting controls. Refer to the wiring diagram on the
duct furnace and set all temperature controls to the temperature settings indicated. The
safety operators for the furnace section setpoints are given below for most furnace
installations, however refer to the wiring diagram.
High Limit 200°F (93°C) & 210°F(99°C) -- Adjust Burner Air Switch To Field Conditions
Fan Switch 125°F (52°C) ON 90°F (32°C) OFF --Temperature Control Up To Customer
11
9. Set thermostat in "OFF" position and turn duct furnace control switch "ON" (manual).
10. Check all fan motors for correct rotation.
nameplate wiring diagram).
If incorrect, reverse rotation (see motor
11. Check the amperage draw of each motor. Refer to rating plate for Full Load Amps
(FLA). If actual motor load is significantly different than rated, take corrective action.
12. Re-check voltage at duct furnace disconnect switch with the duct furnace running. If the
power is not within 10% of rated, shut duct furnace down and consult electric utility
company. Voltage should be within 2% on all phase to phase readings when compared
to each other. A 2% voltage difference could cause as much as a 20% current
imbalance.
13. Ensure that the flue is in place and as noted in 2.7 line 10 Exhaust Stacks and Venting.
14. Set the operating controls, thermostat, remote panel switches, etc., to allow heating
operation of the duct furnace.
15. Initial start up has a tendency to relieve the tightness of nuts, bolts and set screws. Recheck for tightness of hold down bolts, all set screws and keys, and tighten if necessary
after approximately eight (8) hours of continuous operation.
3.2 Combustion Operation
CAUTION
DO NOT relight pilot or start burner when the heat exchanger is very hot, full of gas.
NOTE: When starting up the duct furnace for the first time or if the duct furnace has been
shut down for an extended period of time the same start-up procedures, as outlined in
sections 3.2 and 3.3, should be followed.
1. Refer to burner manufacturer’s Installation, Operation, and Maintenance Instructions for
proper set-up, operation, and settings. Turn on the main and pilot (if applicable) manual
shutoff valves upstream of the firing rate shutoff valve and check for leaks on duct
furnace piping, correct leaks.
2. Check the gas supply pressure to the duct furnace, making sure it does not exceed the
maximum on the duct furnace rating plate.
3. Connect test instruments, meters, and thermometers on the furnace and controls to
measure and record the appropriate data.
4. Close the main manual valve, leaving the pilot open (if applicable).
5. Set the thermostat at highest setting and energize the heating control - burner motor
starts, closing the air switch and energizing the ignition control.
6. With power supplied to the ignition controller and all the safety limiting devices are
satisfied, a 30 - 90 second pre-purge will start, the pilot valve (if applicable) or main gas
valve is energized and a 6-15 second trial to ignite. If the flame sensing probe fails to
prove the pilot or main flame, it de-energizes the spark igniter and the controller will
lockout on flame failure (10-30 seconds). This safety step is performed to establish the
flame sensing, and test any of the safety devices before main burner light off.
12
7. Frequently the cause for safety lockouts relates to gas pressures that are too high, and
or combustion air dampers not set correctly. Cycle pilot several times to make sure that
the combustion air and pilot gas pressure is sufficient to provide instant ignition, and a
stable flame. Check to make sure the pilot flame signal is steady. Pilot regulator
adjustment may be necessary if the adjustment of the needle valve does yield the
required flame signal (if applicable).
8. Install a manometer at the test port to check burner manifold pressure.
9. Once pilot has been established (if applicable), the main manual valve is turned on.
Reset the controller and the ignition sequence will recycle. Once the main automatic
gas valve is energized the burner will light, and the control valve will modulate to
thermostat setpoint. Check to make sure the main flame signal is steady.
10. If the burner does not light within a few seconds after pre-purge shut the burner off and
repeat the previous steps.
11. Check the combustion air setting. The duct furnace has been test fired in the factory for
firing rate and combustion. Field conditions may require adjustments to be made.
These checks should be done by a qualified service man.
a) When the main flame is established, check the gas manifold pressure at the test
points nearest the burner, downstream of the gas control valve. Check the nameplate
for the correct pressure and adjust the appliance regulator if necessary.
b) Check the CO and O2 reading at maximum and minimum inputs shown on the rating
label. O2 readings typically range from 4-10%. CO readings should not exceed 400
PPM at any time. Adjust the air/gas ratios with the control linkages making fine
adjustments before measuring again.
c) Ensure proper overfire draft at test port in burner section is set per nameplate.
d) Visually observe the flame and insure that the flame does not impinge on the heat
exchanger surface and that there are no hot spots on the combustion chamber.
e) Check all gas piping again for leaks using a soap bubble solution.
f) When the duct furnace installation is complete, recheck the amperage draw of each
motor.
g) Insure all safety controls are operative, i.e., flame relay, high limit, air proving
switches, etc.
h) Reset all operating controls back to proper set-points for normal running conditions.
3.3 High Altitude Operation
The rated output of gas-burning appliances decreases with higher altitudes. For IFD series
duct furnace installations at altitudes above 2,000 feet (610 m), the furnace shall be
derated 4 percent for each 1,000 feet (305 m) of altitude above sea level. Factory testing
and rating plate information is recorded on sea level conditions. High altitude ratings may
be obtained by a change in manifold pressure when the appliance is equipped with a gas
pressure regulator. Appliances must be suitably marked to indicate their altitude adjusted
input rating.
13
3.4 Shut-down Instructions
EMERGENCY SHUT-DOWN
•
Set the disconnect switch to the "OFF" position
•
Close the main manual firing valve in the manifold on gas fired duct furnaces
NOTE: The installer must clearly identify all emergency shut-off devices
1. De-energize the heating control, turning the burner off.
2. Close the Manual Firing Valve in the manifold on gas fired duct furnaces.
3. If the duct furnace was firing at the time of shut down allow the main blower to run for a
sufficient period to cool off the heat exchanger. The duct furnace may have an
automatic blower override that will perform this function automatically, running the
blower until the air reaches a cool enough temperature.
4. Turn the duct furnace control to the "OFF" position.
5. Set the main power disconnect to the duct furnace to the "OFF" position.
6. Close the Main Manual Shut-Off Valve if the burner is shut down for an extended period
of time to prevent gas leaking into the combustion chamber.
7. If the duct furnace is to remain idle for an extended period, it is important that the fan
and motor shafts be rotated by hand so that the grease can be spread on the bearing
parts to avoid corrosion by moisture condensation and accumulation.
3.5 Suggested Tools And Instruments
1. Volt/Ohm Meter
5. Ammeter
2. D.C./Microammeter
6. U-Tube Manometer (0-10” W.C.)
3. Stack & Temperature Thermometer
7. Flue Gas Test Equipment
4. Gas Pressure Gauge
8. Standard Hand Tools
14
3.6 Troubleshooting
Refer to burner manufacturer’s IOM for additional troubleshooting information.
Symptom
Cause
Remedy
A. Burner motor does not operate.
1.
2.
3.
Low or no voltage.
Fuse(s) blown.
Customer’s interlock not closed
or connected.
4. Burner “Manual / Auto” switch in
“Off” position.
5. Safety and limit circuits open.
6. Ignition control not closed.
7. Overload protection on motor or
starter tripped.
8. Motor may be defective or
incorrectly wired.
9. Burner relay not closed.
10. Pre-purge timer not closed.
1.
2.
3.
B. No voltage at flame safeguard
relay input terminals.
1.
See burner motor does not
operate Cause 1,2,3,4,5, & 10.
2. Burner motor air proving switch
open.
1. See technical data sheets on
flame safeguard relay.
1.
See burner motor does not
operate Remedy 1,2,3,4,5, & 10.
2.
Check for correct rotation
and or adjustment of switch.
1. Determine the cause of lockout.
Reset the flame safeguard relay.
1.
Manual pilot shut-off valve
closed (if applicable).
2. Inlet gas pressure lower than
minimum gas pressure required.
3. No gas through pilot regulator
with sufficient inlet gas pressure
(if applicable).
4. No gas flow through pilot
solenoid valve (if applicable).
1.
Slowly open valve.
2.
Increase gas pressure.
3.
5.
Type of gas supplied (natural gas
or propane) different than shown
on unit rating plate.
Flame detection system not
sensing pilot flame. (See section
for servicing burner).
5.
Clear obstruction in vent orifice
or line, replace if defective.
Check for proper installation, and
voltage. Correct or replace if
defective.
Connect to proper fuel supply of
contact factory for field
conversion parts.
U.V. Sensor – Clean lens, check
wiring and spark rod.
Flame Rod - Assure rod is in
pilot flame, check wiring, and
flame rod.
No voltage on secondary side of
ignition transformer.
7. Check wiring. Replace transformer
if defective.
C. Flame safeguard relay goes into
safety shutdown (Lockout).
D. Pilot does not light after prepurge has timed out and voltage
is present on flame safeguard
output terminals.
6.
7.
15
Check power source.
Replace fuse(s).
Close or connect customer
interlock.
4.
Place switch in “Manual /
Auto” position.
5.
Close safety and limit
circuits.
6.
Check for power or replace.
7.
Reset the motor or starter and
check amps.
8.
Turn power off and check
power and wiring.
9.
Check for power or replace.
10.
Check for power or replace.
4.
6a.
6b.
E. If pilot does not light after prepurge has timed out and there is
no voltage at flame safeguard
relay output terminals.
F. If there is no heat with pilot OK
(if applicable) and voltage is
present at flame safeguard relay
output terminals.
1.
See technical data sheets on flame
safeguard relay.
1. Check wiring and replace if
defective.
1.
Manual gas shut-off valve closed.
1.
2.
No gas on outlet side of regulator
with proper inlet pressure.
2.
3.
No gas on outlet side of butterfly
valve or actuator with proper
inlet pressure.
Burner does modulate.
3.
1. See technical data sheets on flame
safeguard relay.
1.
4.
G. If there is no heat with pilot OK
and no voltage is present at flame
safeguard relay output terminals.
16
4.
Turn heat off-on switch to the off
position. Slowly open all manual
gas shut-off valves.
Clear obstruction in vent orifice
or line. Check for correct size
spring. Replace if defective.
Check wiring, voltage, and
adjustment. Correct wiring or
replace if defective.
Check wiring and replace if
defective.
Check wiring and replace if
defective.
3.7 Final Checks and Adjustments
Detectable Carbon Monoxide (CO)
With the gas input pressure established, the flue
gas analysis can now be preformed. This is done
at the stack.
•
•
•
•
The following readings should be taken but not
limited to:
Fuel input too high
Not enough burner air
Restricted draft
Flame impingement
Excessive Stack Temperature
CO2% Net Stack Temperature
O2% Combustion Efficiency
CO %
•
•
•
If necessary, make adjustments on burner air
shutter. DO NOT change the fuel input rate.
Draft setting too high
Excess burner air
Fuel input too high
Low Oxygen (O2)
The following list covers general combustion problems
and some of the possible cures. Conditions may vary
in the field. Refer to combustion chart for efficiency.
•
Oxygen reading must always be a
positive percentage
Cycle burner several times to ensure smooth light off
and proper operation. Visually observe the flame
pattern. There must be no flame impingement or hot
spots on the combustion chamber that could cause
scaling.
CAUTION:
Check local codes for maximum
allowable percentages and amounts of emissions.
Low Carbon Dioxide (CO2)
•
•
•
Check voltage and amperage on all motors.
Fuel input too low
Excess burner air
Wrong draft setting
Check all dampers, linkages, and locking quadrants
to make sure they are secure and operating
correctly.
Safety and Controls Checkout
burner to cycle off. Return the adjustment to its
original setting.
Flame Safeguard – Close the last manual gas
valve before burner. Operate unit in heat mode.
After pilot flame has been established, close
manual pilot gas valve (if applicable). The flame
safeguard must trip out within 15 seconds.
Air Pressure Switches – The air pressure
switches can be checked by turning the adjusting
screw to call for a higher pressure than is normally
used on the system. Recycle is automatic when
the switch returned to its original setting. If the
burner or draft proving switches open, this could
cause the flame safeguard to go into lockout
mode.
Gas Pressure Switches – The low gas pressure
switch will trip out and must be reset before
resuming operation when the inlet gas shut off
valve is turned off, or inlet gas pressure is lower
than the trip point. The high gas pressure switch
can be checked by reducing the setting of its trip
point lower than the burner operating pressure.
The switch should trip out and shut off the burner.
Return the adjustment to its original setting and
reset to resume operation.
Limit Controls - The limit controls are checked
by adjusting control to a lower temperature setting
while the unit is operating on high fire and observe
cut-off. Return the adjustment to its original
setting. Manual reset may be required on some
controls.
Temperature Controls The temperature
controls are checked by adjusting control to a
higher temperature to allow burner to cycle on.
Adjust control to a lower temperature to allow
Make sure all the safety and controls are
working properly.
17
4.0 MAINTENANCE
If the duct furnace requires stopping to service, follow the section 3.0 on shutting
the duct furnace down and starting up.
4.1 Recommended Maintenance
NOTE: The following recommended maintenance schedule should be followed every 6
months unless otherwise specified below. It is highly recommended to schedule the
maintenance of the equipment in the spring and fall as equipment demands are commonly
most critical after these periods and serve as good prevention practice.
1. Electrical - Check all wiring for loose connections. Check voltage at the duct furnace
(while in operation). Check amperage draw against nameplate rating. All contactors
should be inspected to ensure that contacts are clean and are making good contact. If
contacts are pitted or burned badly, replace contactor points. Single phasing and motor
burnouts may result from bad contacts. Check all fuses and replace blown fuses with
equivalent size and type.
2. Gas Combustion - Check all fittings, valves and lines for leaks. Check the burner; clean
and adjust if necessary. Check the flame sensor; clean if necessary. Check the fuel
supply pressure to the duct furnace and the manifold pressure. Check and clean the
vent screen if necessary. Refer to burner manufacturer’s IOM for servicing the burner.
3. Controls - Clean and recalibrate all controls and check for proper operation. Repair or
replace any controls found faulty. Check all damper controls and balancing points for
fresh air requirements, tighten any linkages.
4. Motor Lubrication - Refer to motor manufacturer for lubrication recommendations. On
motors having grease drain plugs, remove the plugs and operate the motor for 15
minutes before replacing plugs. Do NOT over grease.
Hours of Service
(Hours / Day)
Re-Grease Interval
Up to 7.5 HP
10 to 40 HP
Over 40 HP
Less than 12
5 Years
3 Years
1.5 Years
More than 12
2 Years
1 Year
9 Months
Motors that run in hot or severe dirt or wet conditions, should be greased at least every six
months.
5. Furnace - Furnaces should be inspected at the beginning of heating season, and every
4 months of usage under normal circumstances. If the furnace is exposed to severe
conditions where exposure to dust, soot, or other impurities contained in the air, a more
frequent inspection is recommended.
•
Clean the burner wheel and rotate the wheel to ensure free movement and tightness
•
Check ignition spark and adjust if necessary
•
Inspect and clean ignition electrodes
•
Check flame supervisor relay flame signal
•
Inspect all safety controls and replace if necessary
18
•
Inspect the flue for blockages. If excessive contamination is present, flush out the flue
by removing the exhaust vent pipe and use a water hose to rinse out the contamination.
Water and contaminants will wash out of the condensate drain. It may be advisable to
temporarily disconnect the normal drain line to prevent a buildup of residue in the drain
system when performing a flush out.
•
Clean the burner.
•
Do a flue gas analysis.
•
Inspect area to make sure that no combustible or hazardous material has been stored
within clearances as shown on the rating plate.
•
Check for operation of the automatic gas shut off valves, and check them for leakage at
the pressure test ports.
•
Inspect all regulators, relief valves, motorized valves, solenoid valves, vent valves, and
safety shut off valves. Check their operation and clean as necessary.
•
Inspect and clean all drip legs in fuel lines and in the flue.
•
Inspect the combustion chamber for carbon deposits, soot, scale or rust. Clean if
necessary. If there is evidence of flame impingement, a complete burner adjustment
must be made.
•
Follow section 3.0 for all details referring to burner operation and start-up.
6. General - Check for any vibration or unusual noise. If any are observed, locate the
cause and correct. Check the condensation lines for any blockages or leaks. Check all
piping and fittings for any fluid/gas leaks. Refer to manufacturer literature provided for
maintenance requirements of optional equipment.
4.2 Recommended Spare Parts
It is recommended that any spare parts required should be ordered at the time the
installation is accepted by the Owner. Spare parts allow the duct furnace to be put back
into service with minimum disruption in the event of failure. The list of spare parts outlined
herein is considered minimum. Installations in remote locations might require more spare
parts than listed. Please contact our Parts and Service Department for recommendations.
Spare Parts
Quantity
Part
2 Sets
Fuses
1 pcs.
Flame sensor
1 pcs.
Spark Rod
1 set
Motor Thermal O/L
1 pcs.
Flame Supervisor
19
5.0 SPECIFICATIONS
The attached literature pertains to the specific duct furnace details
20